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- Dec 20, 2012
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I would use the largest diameter end mill you have and take it in one pass. This is a simple profiling cut for an end mill and the biggest problem will be to stabilize the material so it can sustain the forces of the cut without moving around. Obviously, clamping it horizontally would be ideal but if you must cut it vertically then it is going to vibrate unless you support it; clamping additional support pieces on either side would work.
As for why I would take this in one pass, it is mainly to utilize the cutting edges efficiently. Plunging in tiny bites is fine if all you have is a tiny end mill but if you have a larger one then you will wear the end and sides of your end mill much more than if you took a single pass. As long as you get the cutting speed and feeds right, an end mill will handle this cut easily.
Keep in mind that the material and the end mill will deflect; you can't get away from it. If you just need to get the material off then take it in one pass. If the cut has to be accurate, rough it in one pass and finish it with a second pass. If you want to get even more practical, rough it with a roughing end mill and finish it with a sharp new end mill.
As for why I would take this in one pass, it is mainly to utilize the cutting edges efficiently. Plunging in tiny bites is fine if all you have is a tiny end mill but if you have a larger one then you will wear the end and sides of your end mill much more than if you took a single pass. As long as you get the cutting speed and feeds right, an end mill will handle this cut easily.
Keep in mind that the material and the end mill will deflect; you can't get away from it. If you just need to get the material off then take it in one pass. If the cut has to be accurate, rough it in one pass and finish it with a second pass. If you want to get even more practical, rough it with a roughing end mill and finish it with a sharp new end mill.